Headlight switch failed

My headlight switch failed. The headlights would come up and turn on but the dash lights and tail/running lights were not working. I searched the forum archives and found that this is a very common problem. The price for a new switch ranges from ~$150 - ~$200. Apparently dealerships charge up to ~$700 for parts and labor.

I decided to do exploratory surgery on the switch being that it was already “broken.”
I referenced the following thread for information on removal of the switch:
Multi-function switch swap questions
http://forums.corvetteforum.com/c5-tech/1274548-multi-function-switch-swap-questions.html

Opening the switch and finding the problem was easy. Initially I completely removed the switch but ended up plugging it back up while diagnosing the problem.
I found that the contact points that actuate the dash and running lights had lost too much spring tension to close tightly enough to make a good electrical connection.
To sum it up quickly I simply increased the tension of the contacts so they will close with more force. Problem solved. Price $0.
How long will this repair last? I have no idea but I will update this post if it fails before this thread goes into the archives.

In reality, it took me a few hours of trial and error to finally figure it all out and get it right. I could do the job MUCH faster now. It takes about 30 to 60 minutes to disassemble the car, remove the switch, reinstall the switch, and re-assemble the car.
Between all that, the switch repair should take less than an hour.

Here’s a few quick pics to give an idea of what it looks like:

You only need to remove the three long screws. The short one holds the other half of the switch together.

Remove the grey colored shield/cover.

This contact point fails to close properly causing your dash lights and running lights to remain off. When the headlights are turned on.

To adjust the tension on these contact points, use needle nose pliers to slide the two modules out of the switch. The arrow points to good places to pull from.

To increase tension on the contact points, bend these tabs outward. This forces the points to close together tighter.
If simply bending these tabs outward doesn’t create enough pressure on the contacts, you can bend these tabs inward, thus raising the contacts, then bend the contact arms downward followed by bending the tabs outwards for increased overall pressure.
I cannot think of a better way to word this so just study your options carefully while performing this adjustment.

Just another view.

Based on research about improving the performance of contacts, do not use dielectric grease on the contacts. It will reduce their performance. Dielectric grease is excellent for electrical contacts that are bolted together, clamped together, plugs, etc. but not for contact points.

I ended up lightly cleaning the contacts with 2000 grit sand paper followed by alcohol and a toothbrush.

This repair certainly isn’t for everyone as buying/installing a new switch is a sure cure but for those who like to tinker should find it to be a worthwhile adventure.

I plan to shop around for a good deal on a spare switch just in case this one doesn’t hold up.

Thanks to Miker on Corvette Forum

Headlight switch failed. Decided to repair instead of replace…

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